EP1559680B1 - Heat-resistant exfoliated graphite sheet - Google Patents

Heat-resistant exfoliated graphite sheet Download PDF

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EP1559680B1
EP1559680B1 EP03798498A EP03798498A EP1559680B1 EP 1559680 B1 EP1559680 B1 EP 1559680B1 EP 03798498 A EP03798498 A EP 03798498A EP 03798498 A EP03798498 A EP 03798498A EP 1559680 B1 EP1559680 B1 EP 1559680B1
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carbon number
expanded graphite
acid
weight
group
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EP1559680A4 (en
EP1559680A1 (en
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Shuichi OILES CORPORATION Fujisawa Plant KUBOTA
Kouhei OILES CORPORATION Fujisawa Plant KUROSE
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Oiles Corp
Oiles Industry Co Ltd
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Oiles Industry Co Ltd
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    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B32/00—Carbon; Compounds thereof
    • C01B32/20—Graphite
    • C01B32/21—After-treatment
    • C01B32/22—Intercalation
    • C01B32/225—Expansion; Exfoliation
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
    • C04B35/52—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbon, e.g. graphite
    • C04B35/536—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbon, e.g. graphite based on expanded graphite or complexed graphite
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K21/00—Fireproofing materials
    • C09K21/06—Organic materials
    • C09K21/12—Organic materials containing phosphorus
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/44—Metal salt constituents or additives chosen for the nature of the anions, e.g. hydrides or acetylacetonate
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/30—Self-sustaining carbon mass or layer with impregnant or other layer

Definitions

  • the present invention relates to a heat-resistant expanded graphite sheet, and more particularly to a heat-resistant expanded graphite sheet excelling in resistance to oxidative wear at high temperatures.
  • An expanded graphite sheet is formed by the following process: Graphite such as natural graphite, Kish graphite, or pyrolytic graphite is treated with concentrated sulfuric acid, concentrated nitric acid, concentrated sulfuric acid and potassium chlorate, concentrated sulfuric acid and potassium nitrate, a strong oxidizing agent such as a hydrogen peroxide, or a halide of bromine, aluminum chloride, or the like, to thereby form an intercalation compound.
  • Graphite particles (acid-treated graphite material) formed in this intercalation compound are rapidly heated, i.e., are subjected to heating treatment, for instance, at high temperatures of 950°C or more for 1 to 10 seconds to produce cracked gas.
  • Gaps between graphite layers are expanded by its gas pressure to form expanded graphite particles, and these expanded graphite particles are subjected to compression forming or roll forming in the presence or absence of a binder, thereby forming an expanded graphite sheet.
  • the expanded graphite sheet thus manufactured has heat resistance possessed by graphite itself and has flexibility; therefore, the expanded graphite sheet excels in formability such as bending and compression forming. Therefore, the expanded graphite sheets are used in extensive fields of, for example, gaskets, sealing, heat insulating material, cushion material, and the like.
  • expanded graphite particles for forming this expanded graphite sheet those exhibiting low expansion rates of 20 to 70 times and those exhibiting high expansion rates of 200 to 300 times are used.
  • the binder is inevitably used for sheet formation, a decline in purity and a decline in physical properties result.
  • the above-described expanded graphite sheet excels in various physical properties; however, if it is used in air in a high-temperature range exceeding 700°C in terms of its working conditions, there is a problem in heat resistance, resulting in the oxidative wear of graphite. Hence, there is a drawback in that the rate of oxidative wear is high.
  • an expanded graphite sheet has been proposed in which expanded graphite particles exhibiting a low expansion rate are used, and phosphoric acid or a phosphate is contained in the expanded graphite particles to suppress the oxidation of graphite (published in JP-B-54-30678 ).
  • this publication it is disclosed that sheet formation is made possible by the use of phosphoric acid or a phosphate without using an adhesive.
  • the adhesive is basically not used, various physical properties as the expanded graphite sheet, particularly mechanical properties, uniformity of the sheet, and the like, are not necessarily satisfactory.
  • its resistance to oxidation is improved, in cases where the expanded graphite sheet is exposed for long periods of time, oxidative wear is intense, and the resistance to oxidation is not necessarily satisfactory.
  • JP 10101316 discloses the formation of expanded graphite sheets by compounding expanded and unexpanded graphite particles with an organic phosphate acid or ester and forming them into a sheet.
  • the present invention has been devised in view of the above-described circumstances, and its object is to provide a heat-resistant expanded graphite sheet which demonstrates the action of suppressing the oxidation of graphite even in a high-temperature range exceeding 700°C and exhibits a high rate of oxidative wear resistance.
  • a heat-expanded graphite sheet in accordance with a first aspect of the invention comprises an organic phosphorus compound selected from the group consisting of an organic phosphonic acid and an ester thereof, an organic phosphinic acid and an ester thereof, a phosphoric acid ester, a phosphorus acid ester, and a hypophosphorous acid ester, said organic phosphorus compound being dispersedly contained in a proportion of 0.1 to 10% by weight, and graphite particles which are expanded graphite particles having an expansion rate of 200 to 300 times.
  • heat resistance is imparted by the organic phosphorus compound dispersedly contained in the sheet, the rate of oxidative wear resistance is high even in a wide temperature range from normal temperature to 700°C or higher, and the heat-resistant expanded graphite sheet can be used in various applications.
  • this sheet since this sheet possesses various properties including such as flexibility, easy workability, and the like, which are required for the expanded graphite sheets of this type, molding into a shape corresponding to the application is possible.
  • the content of the organic phosphorus compound is less than 0.1% by weight, it is impossible to make a sufficient contribution to heat resistance, and it is impossible to remarkably improve the rate of oxidative wear resistance of the sheet. Meanwhile, if the contents exceeds 10.0% by weight, further improvement in the heat resistance cannot be expected, and an effect is not recognised in further improvement of the rate of oxidative wear resistance. In addition, if the content exceeds 10.0% by weight, a tendency of making the sheet hard is shown, hampering the flexibility which the sheet possesses.
  • the organic phosphorus compound favourably reduces the oxidative wear of the expanded graphite.
  • an organic phosphonic acid or its ester which is represented by the following general formula (1) is suitably used: in the above formula (1), R 1 is an alkyl group having a carbon number of 1 to 10, an aryl group having a carbon number of 6 to 18, or an aralkyl group consisting of an alkylene portion having a carbon number of 1 to 10 and an aryl portion having a carbon number of 6 to 18, and each of R 2 and R 3 is a hydrogen atom, an alkyl group having a carbon number of 1 to 10, an aryl group having a carbon number of 6 to 18, or an aralkyl group consisting of an alkylene portion having a carbon number of 1 to 10 and an aryl portion having a carbon number of 6 to 18.
  • an organic phosphinic acid or its ester which is represented by the following general formula (2) is suitably used: in the above formula (2), R 4 is an alkyl group having a carbon number of 1 to 10, an aryl group having a carbon number of 6 to 18, or an aralkyl group consisting of an alkylene portion having a carbon number of 1 to 10 and an aryl portion having a carbon number of 6 to 18, and each of R 5 and R 6 is a hydrogen atom, an alkyl group having a carbon number of 1 to 10, an aryl group having a carbon number of 6 to 18, or an aralkyl group consisting of an alkylene portion having a carbon number of 1 to 10 and an aryl portion having a carbon number of 6 to 18.
  • each of R 7 , R 8 , and R 9 is a hydrogen atom, an alkyl group having a carbon number of 1 to 10, an aryl group having a carbon number of 6 to 18, or an aralkyl group consisting of an alkylene portion having a carbon number of 1 to 10 and an aryl portion having a carbon number of 6 to 18, providing that a case where all of them are hydrogen atoms is excluded.
  • each of R 10 , R 11 , and R 12 is an alkyl group having a carbon number of 1 to 10, an aryl group having a carbon number of 6 to 18, or an aralkyl group consisting of an alkylene portion having a carbon number of 1 to 10 and an aryl portion having a carbon number of 6 to 18, and each of R 13 and R 14 is a hydrogen atom, an alkyl group having a carbon number of 1 to 10, an aryl group having a carbon number of 6 to 18, or an aralkyl group consisting of an alkylene portion having a carbon number of 1 to 10 and an aryl
  • hypophosphorous acid ester a hypophosphorous acid diester (phosphonite) which is represented by the following general formula (6) or a hypophosphorous acid monoester which is represented by the following general formula (7) is suitably used: in the above formulae (6) and (7), R 15 is a hydrogen atom, an alkyl group having a carbon number of 1 to 10, an aryl group having a carbon number of 6 to 18, or an aralkyl group consisting of an alkylene portion having a carbon number of 1 to 10 and an aryl portion having a carbon number of 6 to 18, and each of R 16 , R 17 , and R 18 is an alkyl group having a carbon number of 1 to 10, an aryl group having a carbon number of 6 to 18, or an aralkyl group consisting of an alkylene portion having a carbon number of 1 to 10 and an aryl portion having a carbon number of 6 to 18.
  • the present invention by compounding the acid-treated graphite material with a predetermined amount of an organic phosphorus compound, it is possible to provide a heat-resistant expanded graphite sheet which exhibits a high rate of oxidative wear resistance even at temperatures exceeding 700°C.
  • the acid-treated graphite material While the acid-treated graphite material is being agitated, the acid-treated graphite material is compounded with a powder or a solution of an organic phosphorus compound in a predetermined proportion of amount and is agitated uniformly to obtain a mixture. This mixture is subjected to heating (expansion) treatment for 1 to 10 seconds at temperatures of 950 to 1200°C to produce cracked gas. The gaps between graphite layers are expanded by its gas pressure to form expanded graphite particles (expansion rate: 200 to 300 times). These expanded graphite particles are fed to a twin roller apparatus and is subjected to roll forming, thereby fabricating a heat-resistant expanded graphite sheet having a desired thickness.
  • the acid-treated graphite material is fabricated in the same way as in the above-described manufacturing method I.
  • This acid-treated graphite material is subjected to heating (expansion) treatment for 1 to 10 seconds at temperatures of 950 to 1200°C to produce cracked gas.
  • the gaps between graphite layers are expanded by its gas pressure to form expanded graphite particles (expansion rate: 200 to 300 times).
  • the expanded graphite particles thus obtained are compounded with a powder or a solution of an organic phosphorus compound in a predetermined proportion of amount and is agitated uniformly to obtain a mixture.
  • This mixture is fed to the twin roller apparatus and is subjected to roll forming, thereby fabricating a heat-resistant expanded graphite sheet having a desired thickness.
  • the heat-resistant expanded graphite sheets fabricated in the above-described manufacturing methods I and II are flexible sheets which contain predetermined amounts of an organic phosphorus compound and expanded graphite.
  • the organic phosphorus compound dispersedly contained in the heat-resistant expanded graphite sheet demonstrates the action of suppressing the oxidative wear of the expanded graphite at high temperatures exceeding 700°C.
  • the content of the organic phosphorus compound is 0.1 to 10% by weight, preferably 0.5 to 7.0% by weight, and more preferably 2.0 to 5.0% by weight.
  • the amount of content of the organic phosphorus compound exerts an effect on the flexibility of the heat-resistant expanded graphite sheet. If its content exceeds 10.0% by weight, a tendency of the sheet itself to become hard and brittle is shown, and the formability and workability at the time of formation into a shape and the like according to various applications are hampered. Meanwhile, if the content of the organic phosphorus compound is less than 0.1% by weight, it is difficult to sufficiently impart heat resistance, and the oxidation suppressing effect at high temperature is not sufficient.
  • organic phosphorus compounds it is possible to cite an organic phosphonic acid or its ester, an organic phosphinic acid or its ester, a phosphoric acid ester, a phosphorous acid ester, a hypophosphorous acid ester, and the like.
  • an organic phosphonic acid or its ester which is represented by the following general formula (1) is suitably used: in the above formula (1), R 1 is an alkyl group having a carbon number of 1 to 10, an aryl group having a carbon number of 6 to 18, or an aralkyl group consisting of an alkylene portion having a carbon number of 1 to 10 and an aryl portion having a carbon number of 6 to 18, and each of R 2 and R 3 is a hydrogen atom, an alkyl group having a carbon number of 1 to 10, an aryl group having a carbon number of 6 to 18, or an aralkyl group consisting of an alkylene portion having a carbon number of 1 to 10 and an aryl portion having a carbon number of 6 to 18.
  • the alkyl group is a straight-chain or branched-chain alkyl group (e.g., a methyl group, an ethyl group, a propyl group, an isopropyl group, an n-butyl group, a sec-butyl group, a tert-butyl group, or the like) preferably having a carbon number of 1 to 10, more preferably having a carbon number of 1 to 6.
  • the aryl group is an aryl group (e.g., a phenyl group, a naphthyl group, an ethylphenyl group, a tolyl group, a xylyl group, or the like) preferably having a carbon number of 6 to 18, more preferably having a carbon number of 6 to 10.
  • aryl group e.g., a phenyl group, a naphthyl group, an ethylphenyl group, a tolyl group, a xylyl group, or the like
  • the aralkyl group is one (e.g., a benzyl group, a naphthylmethyl group, or the like) whose alkylene portion is straight-chain or branched-chain alkylene preferably having a carbon number of 1 to 10, more preferably having a carbon number of 1 to 6, and whose aryl portion is aryl preferably having a carbon number of 6 to 18, more preferably having a carbon number of 6 to 10.
  • methylphosphonic acid ethylphosphonic acid, phenylphosphonic acid, tolylphosphonic acid, benzylphosphonic acid, methylphosphonic acid methyl, methylphosphonic acid dimethyl, methylphosphonic acid diphenyl, phenylphosphonic acid diethyl, and the like.
  • an organic phosphinic acid or its ester which is represented by the following general formula (2) is suitably used: in the above formula (2), R 4 is an alkyl group, an aryl group, or an aralkyl group, and each of R 5 and R 6 is a hydrogen atom, an alkyl group, an aryl group, or an aralkyl group.
  • R 4 is an alkyl group, an aryl group, or an aralkyl group
  • each of R 5 and R 6 is a hydrogen atom, an alkyl group, an aryl group, or an aralkyl group.
  • the alkyl group, the aryl group, and the aralkyl group are the same as those described above.
  • methylphosphinic acid ethylphosphinic acid, diethylphosphinic acid, methylethylphosphinic acid, phenylphosphinic acid, methylphenylphosphinic acid, diphenylphosphinic acid, methylphosphinic acid ethyl, dimethylphosphinic acid ethyl, methylphosphinic acid phenyl, phenylphosphinic acid ethyl, and the like.
  • each of R 7 , R 8 , and R 9 is a hydrogen atom, an alkyl group, an aryl group, or an aralkyl group, providing that a case where all of them are hydrogen atoms is excluded.
  • the alkyl group, the aryl group, and the aralkyl group are the same as those described above.
  • methyl phosphate butyl phosphate, phenyl phosphate, diethyl phosphate, diphenyl phosphate, dibenzyl phosphate, trimethyl phosphate, triphenyl phosphate, diphenyl cresyl phosphate, methyl diphenyl phosphate, and the like.
  • a phosphorous acid triester which is represented by the following general formula (4) or a phosphorous acid diester or a phosphorous acid monoester which is represented by the following general formula (5) is suitably used: in the above formulae (4) and (5), each of R 10 , R 11 , and R 12 is an alkyl group, an aryl group, or an aralkyl group, and each of R 13 and R 14 is a hydrogen atom, an alkyl group, an aryl group, or an aralkyl group, providing that a case where both of R 13 and R 14 are hydrogen atoms is excluded.
  • the alkyl group, the aryl group, and the aralkyl group are the same as those described above.
  • hypophosphorous acid ester a hypophosphorous acid diester (phosphonite) which is represented by the following general formula (6) or a hypophosphorous acid monoester which is represented by the following general formula (7) is suitably used: in the above formulae (6) and (7), R 15 is a hydrogen atom, an alkyl group, an aryl group, or an aralkyl group, and each of R 16 , R 17 , and R 18 is an alkyl group, an aryl group, or an aralkyl group.
  • the alkyl group, the aryl group, and the aralkyl group are the same as those described above.
  • dimethyl phosphonite diphenyl phosphonite, dibenzyl phosphonite, diethyl phosphonite, methyl hypophosphite, ethyl hypophosphite, phenyl hypophosphite, and the like.
  • the acid-treated graphite was separated by suction and filtration, and a cleaning operation in which the acid-treated graphite was agitated in 300 parts by weight of water for 10 minutes and was sucked and filtered was repeated twice, thereby sufficiently removing the sulfuric acid content from the acid-treated graphite.
  • the acid-treated graphite from which the sulfuric acid content was removed sufficiently was dried for three hours in a drying furnace held at a temperature of 110°C, and this was used as the acid-treated graphite material.
  • the acid-treated graphite material was compounded with (1) 0.1 parts by weight, (2) 0.5 parts by weight, (3) 1.0 parts by weight, (4) 2.0 parts by weight, (5) 4.2 parts by weight, (6) 6.4 parts by weight, (7) 8.7 parts by weight, and (8) 11.1 parts by weight, respectively, of a powder of phenylphosphonic acid as the organic phosphorus compound, and was agitated uniformly, thereby obtaining 8 kinds of mixtures.
  • These mixtures were subjected to heating treatment for 5 seconds at a temperature of 1000°C to produce cracked gas.
  • the gaps between graphite layers were expanded by its gas pressure, thereby obtaining expanded graphite particles having an expansion rate of 240 times.
  • the phenylphosphonic acid was dispersedly contained in the expanded graphite particles.
  • These expanded graphite particles were subjected to roll forming by being passed through a reduction roll, thereby fabricating expanded graphite sheets having a thickness of 0.38 mm.
  • These expanded graphite sheets respectively contained (1) 0.1% by weight of phenylphosphonic acid and 99.9% by weight of expanded graphite, (2) 0.5% by weight of phenylphosphonic acid and 99.5% by weight of expanded graphite, (3) 1.0% by weight of phenylphosphonic acid and 99.0% by weight of expanded graphite, (4) 2.0% by weight of phenylphosphonic acid and 98.0% by weight of expanded graphite, (5) 4.0% by weight of phenylphosphonic acid and 96.0% by weight of expanded graphite, (6) 6.0% by weight of phenylphosphonic acid and 94.0% by weight of expanded graphite, (7) 8.0% by weight of phenylphosphonic acid and 92.0% by weight of expanded graphite, and (8) 10.0% by weight of phenylphosphonic acid and 90.0% by weight of expanded graphite.
  • the acid-treated graphite material was fabricated in the same way as in the above-described Examples. While 100 parts by weight of the acid-treated graphite material was being agitated, the acid-treated graphite material was compounded with (9) 1.0 parts by weight, (10) 2.0 parts by weight, (11) 4.2 parts by weight, and (12) 6.4 parts by weight, respectively, of a powder of phenylphosphonic acid diethyl as the organic phosphorus compound, and was agitated uniformly, thereby obtaining 4 kinds of mixtures. These mixtures were subjected to heating treatment for 5 seconds at a temperature of 1000°C to produce cracked gas. The gaps between graphite layers were expanded by its gas pressure, thereby obtaining expanded graphite particles having an expansion rate of 240 times. In this expansion treatment process, the phenylphosphonic acid diethyl was dispersedly contained in the expanded graphite particles.
  • expanded graphite particles were subjected to roll forming by being passed through the reduction roll, thereby fabricating expanded graphite sheets having a thickness of 0.38 mm.
  • the expanded graphite sheets thus fabricated respectively contained (9) 1.0% by weight of phenylphosphonic acid diethyl and 99.0% by weight of expanded graphite, (10) 2.0% by weight of phenylphosphonic acid diethyl and 98.0% by weight of expanded graphite, (11) 4.0% by weight of phenylphosphonic acid diethyl and 96.0% by weight of expanded graphite, and (12) 6.0% by weight of phenylphosphonic acid diethyl and 94.0% by weight of expanded graphite.
  • the acid-treated graphite material was fabricated in the same way as in the above-described Examples. While 100 parts by weight of the acid-treated graphite material was being agitated, the acid-treated graphite material was compounded with (13) 1.0 parts by weight, (14) 2.0 parts by weight, (15) 4.2 parts by weight, and (16) 6.4 parts by weight, respectively, of a powder of diphenylphosphinic acid as the organic phosphorus compound, and was agitated uniformly, thereby obtaining 4 kinds of mixtures. These mixtures were subjected to heating treatment for 5 seconds at a temperature of 1000°C to produce cracked gas. The gaps between graphite layers were expanded by its gas pressure, thereby obtaining expanded graphite particles having an expansion rate of 240 times. In this expansion treatment process, the diphenylphosphinic acid was dispersedly contained in the expanded graphite particles.
  • expanded graphite particles were subjected to roll forming by being passed through the reduction roll, thereby fabricating expanded graphite sheets having a thickness of 0.38 mm.
  • the expanded graphite sheets thus fabricated respectively contained (13) 1.0% by weight of diphenylphosphinic acid and 99.0% by weight of expanded graphite, (14) 2.0% by weight of diphenylphosphinic acid and 98.0% by weight of expanded graphite, (15) 4.0% by weight of diphenylphosphinic acid and 96.0% by weight of expanded graphite, and (16) 6.0% by weight of diphenylphosphinic acid and 94.0% by weight of expanded graphite.
  • the acid-treated graphite material was fabricated in the same way as in the above-described Examples. While 100 parts by weight of the acid-treated graphite material was being agitated, the acid-treated graphite material was compounded with (17) 1.0 parts by weight, (18) 2.0 parts by weight, (19) 4.2 parts by weight, and (20) 6.4 parts by weight, respectively, of a powder of phenylphosphinic acid as the organic phosphorus compound, and was agitated uniformly, thereby obtaining 4 kinds of mixtures. These mixtures were subjected to heating treatment for 5 seconds at a temperature of 1000°C to produce cracked gas. The gaps between graphite layers were expanded by its gas pressure, thereby obtaining expanded graphite particles having an expansion rate of 240 times. In this expansion treatment process, the phenylphosphinic acid was dispersedly contained in the expanded graphite particles.
  • expanded graphite particles were subjected to roll forming by being passed through the reduction roll, thereby fabricating expanded graphite sheets having a thickness of 0.38 mm.
  • the expanded graphite sheets thus fabricated respectively contained (17) 1.0% by weight of phenylphosphinic acid and 99.0% by weight of expanded graphite, (18) 2.0% by weight of phenylphosphinic acid and 98.0% by weight of expanded graphite, (19) 4.0% by weight of phenylphosphinic acid and 96.0% by weight of expanded graphite, and (20) 6.0% by weight of phenylphosphinic acid and 94.0% by weight of expanded graphite.
  • the acid-treated graphite material was fabricated in the same way as in the above-described Examples. While 100 parts by weight of the acid-treated graphite material was being agitated, the acid-treated graphite material was compounded with (21) 1.0 parts by weight, (22) 2.0 parts by weight, (23) 4.2 parts by weight, and (24) 6.4 parts by weight, respectively, of a powder of a phosphoric acid ester, specifically diphenyl phosphate, as the organic phosphorus compound, and was agitated uniformly, thereby obtaining 4 kinds of mixtures. These mixtures were subjected to heating treatment for 5 seconds at a temperature of 1000°C to produce cracked gas. The gaps between graphite layers were expanded by its gas pressure, thereby obtaining expanded graphite particles having an expansion rate of 240 times. In this expansion treatment process, the diphenyl phosphate was dispersedly contained in the expanded graphite particles.
  • the expanded graphite sheets thus fabricated respectively contained (21) 1.0% by weight of diphenyl phosphate and 99.0% by weight of expanded graphite, (22) 2.0% by weight of diphenyl phosphate and 98.0% by weight of expanded graphite, (23) 4.0% by weight of diphenyl phosphate and 96.0% by weight of expanded graphite, and (24) 6.0% by weight of diphenyl phosphate and 94.0% by weight of expanded graphite.
  • the acid-treated graphite material was fabricated in the same way as in the above-described Examples. While 100 parts by weight of the acid-treated graphite material was being agitated, the acid-treated graphite material was compounded by spraying with (25) 1.0 parts by weight, (26) 2.0 parts by weight, (27) 4.2 parts by weight, and (28) 6.4 parts by weight, respectively, of a solution of a phosphorous acid ester, specifically triphenyl phosphite, as the organic phosphorus compound, and was agitated uniformly, thereby obtaining 4 kinds of mixtures. These mixtures were subjected to heating treatment for 5 seconds at a temperature of 1000°C to produce cracked gas. The gaps between graphite layers were expanded by its gas pressure, thereby obtaining expanded graphite particles having an expansion rate of 240 times. In this expansion treatment process, the triphenyl phosphite was dispersedly contained in the expanded graphite particles.
  • expanded graphite particles were subjected to roll forming by being passed through the reduction roll, thereby fabricating expanded graphite sheets having a thickness of 0.38 mm.
  • the expanded graphite sheets thus fabricated respectively contained (25) 1.0% by weight of triphenyl phosphite and 99.0% by weight of expanded graphite, (26) 2.0% by weight of triphenyl phosphite and 98.0% by weight of expanded graphite, (27) 4.0% by weight of triphenyl phosphite and 96.0% by weight of expanded graphite, and (28) 6.0% by weight of triphenyl phosphite and 94.0% by weight of expanded graphite.
  • the acid-treated graphite material was fabricated in the same way as in the above-described Examples. While 100 parts by weight of the acid-treated graphite material was being agitated, the acid-treated graphite material was compounded with (29) 1.0 parts by weight, (30) 2.0 parts by weight, (31) 4.2 parts by weight, and (32) 6.4 parts by weight, respectively, of a powder of a hypophosphorous acid ester, specifically dimethyl phosphonite, as the organic phosphorus compound, and was agitated uniformly, thereby obtaining 4 kinds of mixtures. These mixtures were subjected to heating treatment for 5 seconds at a temperature of 1000°C to produce cracked gas. The gaps between graphite layers were expanded by its gas pressure, thereby obtaining expanded graphite particles having an expansion rate of 240 times. In this expansion treatment process, the dimethyl phosphonite was dispersedly contained in the expanded graphite particles.
  • expanded graphite particles were subjected to roll forming by being passed through the reduction roll, thereby fabricating expanded graphite sheets having a thickness of 0.38 mm.
  • the expanded graphite sheets thus fabricated respectively contained (29) 1.0% by weight of dimethyl phosphonite and 99.0% by weight of expanded graphite, (30) 2.0% by weight of dimethyl phosphonite and 98.0% by weight of expanded graphite, (31) 4.0% by weight of dimethyl phosphonite and 96.0% by weight of expanded graphite, and (32) 6.0% by weight of dimethyl phosphonite and 94.0% by weight of expanded graphite.
  • the acid-treated graphite material was fabricated in the same way as in the above-described Examples. While 100 parts by weight of the acid-treated graphite material was being agitated, the acid-treated graphite material was compounded by spraying with an aqueous solution of orthophosphoric acid with a concentration of 84% in proportions of (1) 0.33 parts by weight, (2) 0.99 parts by weight, and (3) 1.66 parts by weight, and was agitated uniformly, thereby obtaining wet mixtures. Thereafter, expanded graphite particles having an expansion rate of 250 times were fabricated in a method similar to those of the above-described Examples, and expanded graphite sheets having a thickness of 0.38 mm were fabricated in a method similar to those of the above-described Examples.
  • the orthophosphoric acid compounded in the acid-treated expanded graphite material undergoes dehydration in the expansion treatment process and produces phosphorus pentoxide.
  • the expanded graphite sheets thus fabricated respectively contained (1) 0.2% by weight of phosphorus pentoxide and 99.8% by weight of expanded graphite, (2) 0.6% by weight of phosphorus pentoxide and 99.4% by weight of expanded graphite, and (3) 1.0% by weight of phosphorus pentoxide and 99.0% by weight of expanded graphite.
  • the acid-treated graphite material was fabricated in the same way as in the above-described Examples. While 100 parts by weight of the acid-treated graphite material was being agitated, the acid-treated graphite material was compounded by spraying with a solution in which aluminum primary phosphate with a concentration of 50% in proportions of (4) 8.4 parts by weight, (5) 17.4 parts by weight, and (6) 38 parts by weight was diluted with 30 parts by weight of methanol, and was agitated uniformly, thereby obtaining wet mixtures.
  • expanded graphite particles having an expansion rate of 250 times were fabricated in a method similar to those of the above-described Examples, and expanded graphite sheets having a thickness of 0.38 mm were fabricated in a method similar to those of the above-described Examples.
  • the expanded graphite sheets thus fabricated respectively contained (4) 4.0% by weight of aluminum primary phosphate and 96.0% by weight of expanded graphite, (5) 8.0% by weight of aluminum primary phosphate and 92.0% by weight of expanded graphite, and (6) 16.0% by weight of aluminum primary phosphate and 84.0% by weight of expanded graphite.
  • the rate of oxidative wear was tested with respect to the expanded graphite sheets obtained in the above-described Examples 1 to 32 and Comparative Examples 1 to 6.
  • the test method is shown by the weight reduction rate (%) of the expanded graphite sheet after the expanded graphite sheet was left to stand for 3 hours in the air held at a temperature of 720°C. Further, a test was conducted on the flexibility of the expanded graphite sheets obtained in the above-described Examples 1 to 32 and Comparative Examples 1 to 6. The results of test are shown by the number of times until the expanded graphite sheet having a width of 10 mm and a length of 100 mm was cut after being bent clockwise and counterclockwise by angles of 90 degrees by using a testing apparatus shown in Fig. 1 . In Fig.
  • reference numeral 1 denotes the expanded graphite sheet; 2, a weight of 50 g; and 3, a bending range. These test results are shown in Tables 1 to 10. Table 1 Examples 1 2 3 4 Expanded graphite Organic phosphorus compound: Phenylphosphonic acid 99.9 99.5 99.0 98.0 0.1 0.5 1.0 2.0 Weight reduction rate (%) 13.0 12.8 12.6 10.5 Flexibility (times) Longitudinal direction 13 13 12 12 Widthwise direction 23 22 22 21 Table 2 Examples 5 6 7 8 Expanded graphite Organic phosphorus compound: Phenylphosphonic acid 96.0 94.0 92.0 90.0 4.0 6.0 8.0 10.0 Weight reduction rate (%) 10.7 11.5 11.7 12.5 Flexibility (times) Longitudinal direction 11 11 11 10 20 20 20 19 Table 3 Examples 9 10 11 12 Expanded graphite Organic phosphorus compound: Phenylphosphonic acid diethyl 99.0 98.0 96.0 94.0 1.0 2.0 4.0 6.0 Weight reduction rate (%) 12.3 10.
  • the heat-resistant expanded graphite sheets in accordance with the Examples exhibit advantages in that, in comparison with the expanded graphite sheets in the Comparative Examples, the heat resistance is improved, and that the rate of oxidative wear resistance is high even at temperatures exceeding 700°C.
  • the heat-resistant expanded graphite sheets in accordance with the Examples possess equivalent properties.

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CN100351175C (zh) 2007-11-28
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